19 th of february 2004 gregory crinum mine 1 gregory crinum mine – rotary breakers gregory rotary...
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19th of February 2004Gregory Crinum Mine1
Gregory Crinum Mine – Rotary Breakers
Gregory Rotary Breaker - Old Lubrication System
Crinum Rotary Breaker - New Lubrication System
19th of February 2004Gregory Crinum Mine2
Rotary Breaker – Lubrication System Improvements
PROBLEMS
• Lubricant being splashed on the Rotary Breaker chain and surrounding structures
• Lubricant spillage causing an imminent workplace and safety issues
• Unnecessary waste of lubricant• Environmental impact (Penetration into the soil,
costly and unsafe disposal)
19th of February 2004Gregory Crinum Mine3
Rotary Breaker – Lubrication System Improvements
Lubricant spillage
• Chain splashing lubricant over surrounding structures
• Pools of lubricant laying underneath Rotary Breaker
•Lubricant deteriorating floor plate and dripping into the ground
19th of February 2004Gregory Crinum Mine4
Rotary Breaker – Lubrication System Improvements
OBJECTIVES
• Improvements to current Automated Lubrication System
• Addition of air operated pump to agitate lubricant prior to pumping
• Addition of brushes for lubricant application• Ensure that lubricant reaches critical points on the
chain
19th of February 2004Gregory Crinum Mine5
Rotary Breaker – Lubrication System ImprovementsCOMPARISON
Previous System Automated Lubrication System: Lubricant
application for 10 seconds every 40 minutes Consumption: 205 Litre Drum of Mobil 630 or BP GR
– XP 220 per month. (Not including down time due to shutdowns or other maintenance factors)
Cost: 205 Litre Drum - $351.35
19th of February 2004Gregory Crinum Mine6
Rotary Breaker – Lubrication System ImprovementsImproved System Automated Lubrication System: 300mL of
Lanotec Heavy Duty Lanolin (HD) applied during 10 seconds every 8 hours (3 applications daily).
Consumption: 205 Litre Drum of Lanotec Heavy Duty
Lanolin (HD) will allow for 683 applications, which is equivalent in time to 7.5 months. (Not including down time due to shutdowns or other maintenance factors).
Cost: 205 Litre Drum – Price on application
19th of February 2004Gregory Crinum Mine7
Rotary Breaker – Lubrication System Improvements
New System Installation
• New Lanotec Lanolin drum
• Air pump installed
• Lubrication lines installed
• Brushes installed
19th of February 2004Gregory Crinum Mine8
Rotary Breaker – Lubrication System Improvements
3-MONTH TRIAL (Started November 2003) Results Improved Automated Lubrication System
• Controlled and efficient application of lubricant• Lubricant application in critical areas• Excessive presence of lubricant in chain and
surrounding structures eliminated• Lubricant waste factor eliminated
19th of February 2004Gregory Crinum Mine9
Rotary Breaker – Lubrication System Improvements
Equipment Life
• Chain life was approx. 4-5mths• Chain life currently 3 years and still going!• Sprockets wear reduced• Deterioration of surrounding structures reduced
19th of February 2004Gregory Crinum Mine10
Rotary Breaker – Lubrication System Improvements
Performance & Costs
• Improved equipment efficiency• Reduced maintenance costs• Increased maintenance intervals• Increased equipment life• Reduction of lubricant drums in stock• Down time and loss of production reduced• Workplace health and safety impact reduced• Disposal costs eliminated
19th of February 2004Gregory Crinum Mine11
Rotary Breaker – Lubrication System Improvements
Environmental
• Lubricant is bio-degradable• Non toxic• Non carcinogenic• Ozone friendly• Safer to dispose
19th of February 2004Gregory Crinum Mine12
Rotary Breaker – Lubrication System Improvements
Results
• No lubricant spillage
• System performing efficiently
• Chain properly lubricated
• Cleaner work area
19th of February 2004Gregory Crinum Mine13
Rotary Breaker – Lubrication System Improvements
COST EFFECTIVE RESULTS 12 Months Expectations
• Savings of $604.19 in lubricant purchase per year• Maintenance costs reduced (equipment, parts and
labour)• Lubricant usage reduced from 2460 Litres (12
drums) to 328 Litres (1.6 drums) per year• Delivery and storage costs reduced• Handling and disposal costs reduced
19th of February 2004Gregory Crinum Mine14
BMA Savings (over 2 yrs) usingthe Lanotec Lubrication System
Old System Lanotec System
Lube System N/A $3,000
Lubricant Cost $9,200 $7,500
Chain replacement(5) $30,000 NIL
Labour on above $3,000 NIL
Lost Production (30hrs) $3,000,000 NIL
TOTAL = $3,042,000 $10,500
SAVINGS (2yrs) = $3,031,500
19th of February 2004Gregory Crinum Mine15
Rotary Breaker – Lubrication System Improvements
INITIAL INVESTMENT
• Chain Lube Pump/Spray unit• Installation
TOTAL COST: Price on application
19th of February 2004Gregory Crinum Mine16
Rotary Breaker – Lubrication System Improvements
CONTACT INFORMATION
MARK PEATEYCHPP MAINTENANCE PLANNERGREGORY CRINUM MINEBHP Billiton Mitsubishi AlliancePO Box 1526Emerald, QLD 4720Phone (+61) 07 4982 8237Fax (+61) 07 4982 8274Email [email protected]
STEVE GREENWESTERN AUSTRALIAN BUSINESS DEVELOPMENT MANAGERLANOTEC AUSTRALIA PTY LTD
Phone (+61) 07 3373 3700Mobile (+61)417 638 004Email [email protected]